BMW HP2 ENDURO Technical specifications

Maintenance instructions for sporty off-roading
HP2 Enduro

Motorcycle data/dealership details
Motorcycle data
Model
Vehicle identification number
Colour code
Date of first registration
Registration number
Dealership details
Person to contact in Service depart-
ment
Ms/Mr
Phone number
Dealership address/phone number
(company stamp)

Details described or illus-
trated in this booklet may
differ from the motorcycle's
actual specification as pur-
chased, the accessories fit-
ted or the national-market
specification. No claims will
be entertained as a result of
such discrepancies.
Dimensions, weights, fuel
consumption and perform-
ance data are quoted to the
customary tolerances.
The right to modify designs,
equipment and accessories is
reserved.
Errors and omissions excep-
ted.
© 2005 BMW Motorrad
Not to be reproduced either
wholly or in part without writ-
ten permission from BMW
Motorrad, After Sales.
Printed in Germany.

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Maintenance in-
structions for sporty
off-roading
These maintenance instruc-
tions were compiled for riders
who want to leave metalled
roads and use their motor-
cycles for sporty off-roading.
Before you go off-roading,
BMW Motorrad recommends
installing the accessories
supplied with the motorcycle.
In this way you can effectively
protect parts of the motor-
cycle that could otherwise be
at risk.
These maintenance instruc-
tions describe the proced-
ures for installing the off-road
accessories and the proced-
ure for removing the number-
plate carrier and the mirrors.
Use the headlight guard
only when off-roading.
Riding on public roads with
the headlight guard fitted to
the motorcycle is prohibited.
Sporty off-roading inevitably
increases wear and tear on
the motorcycle, so extra
checks and maintenance
work over and above those
described in the Rider's
Manual are necessary. They
too are described in this
publication.
All the work described in
these Maintenance Instruc-
tions is supplementary to the
standard maintenance work
described in the "Service"
section of the Rider's Manual.
Please bear in mind that if the
motorcycle is used for sporty
off-roading, you must comply
with these additional mainten-
ance instructions in order to
keep the motorcycle in good
running order.
Some of the work calls for
special tools and a thorough
knowledge of motorcycles.
If you are in doubt consult a
specialist workshop, prefer-
ably your authorised BMW
Motorrad dealer.
Damage not attended
to in good time or inad-
equately repaired can result in
consequential damage to the
motorcycle.
Consult a specialist work-
shop, preferably an author-
ised BMW Motorrad dealer,
as soon as possible if you
discover that the motorcycle
is damaged.

Table of Contents
You can also consult the in-
dex at the end of this Rider's
Manual if you want to find a
particular topic or item of in-
formation.
1 General instructions . . . 3
Notes on these
Maintenance
Instructions . . . . . . . . . . . . . . 4
Abbreviations and
symbols . . . . . . . . . . . . . . . . . . 4
2 Overview . . . . . . . . . . . . . . 5
Conversion work
preparatory to
off-roading . . . . . . . . . . . . . . . 6
Maintenance work . . . . . . . . 6
3 Installing and removing
components . . . . . . . . . . . 9
Removing number-plate
carrier . . . . . . . . . . . . . . . . . . 10
Installing number-plate
carrier . . . . . . . . . . . . . . . . . . 11
Removing mirror . . . . . . . . . 12
Installing mirrors . . . . . . . . . 12
Installing headlight
guard . . . . . . . . . . . . . . . . . . . 12
Installing guard for final
drive . . . . . . . . . . . . . . . . . . . . 13
Installing cylinder
guard . . . . . . . . . . . . . . . . . . . 14
Installing deflector for
footbrake lever . . . . . . . . . . 14
Installing left and right
hand protectors . . . . . . . . . 15
Replacing left and right
hand frame-protector
strips . . . . . . . . . . . . . . . . . . . 18
4 Maintenance . . . . . . . . . 19
Work to be carried out
always before
off-roading . . . . . . . . . . . . . . 20
Work to be carried out
after five hours of riding in
sand, dust or mud . . . . . . . 20
Work to be carried out
after ten hours
off-roading . . . . . . . . . . . . . . 25
Work to be undertaken
once a year. . . . . . . . . . . . . . 29
5 Threaded fasteners . . . 31
Anchorage points, engine
and swinging arm . . . . . . . . 33
Anchorage points, frame
and mounted
components. . . . . . . . . . . . . 34
Anchorage points,
front . . . . . . . . . . . . . . . . . . . . 36
Threaded fasteners, front
wheel . . . . . . . . . . . . . . . . . . . 38
Body-panel screws . . . . . . 38
6 Technical data . . . . . . . . 39
Tightening torques for
internally mounted
components. . . . . . . . . . . . . 40
Tightening torques for
checking threading
fasteners . . . . . . . . . . . . . . . . 42

General instructions
General instructions
Notes on these Maintenance
Instructions ..................... 4
Abbreviations and symbols ...... 4
1
3
z General instructions

Notes on these Main-
tenance Instructions
The work explained in these
Maintenance Instructions
should be carried out in
accordance with the schedule
outlined below. Use the
operating-hours counter
described in the "Operation"
section of the Rider's Manual
to check the operating hours.
Work you must always un-
dertake before leaving sur-
faced roads for sporty off-
roading.
Work you must undertake
after five hours of riding in
mud, dust or sand.
Work you must undertake
after ten hours off-roading.
Work you must undertake
once a year.
You will find detailed informa-
tion on maintenance and re-
pair work in the Repair Manu-
al on the CD-ROM that ac-
companies your motorcycle.
Abbreviations and
symbols
Indicates warnings that
you must comply with for
reasons of your safety and the
safety of others, and to pro-
tect your motorcycle against
damage.
Specific instructions on
how to operate, control,
adjust or look after items of
equipment on the motorcycle.
Indicates the end of an
item of information.
Instruction.
Result of an activity.
Reference to a page
with more detailed in-
formation.
1
4
z General instructions

Overview
Overview
Conversion work preparatory to
off-roading ...................... 6
Maintenance work ............... 6
2
5
z Overview

Conversion work
preparatory to
off-roading
Removing number-plate
carrier ( 10)
Removing mirror ( 12)
Installing headlight guard
( 12)
Installing guard for final
drive ( 13)
Installing cylinder guard
( 14)
Installing deflector for foot-
brake lever ( 14)
Installing left and right hand
protectors ( 15)
Maintenance work
Work to be carried
out always before
off-roading
Checking brake disc wear
( 20)
Checking brake pads for
wear ( 20)
Checking spokes ( 20)
Work to be carried out
after five hours of riding
in sand, dust or mud
Checking alternator drive
belt ( 20)
Checking air filter for dirt
( 21)
Checking ease of move-
ment of footbrake lever
( 23)
Checking ease of move-
ment of shift lever ( 24)
Cleaning slider tubes ( 25)
Work to be carried
out after ten hours
off-roading
Checking air filter for dirt
( 21)
Checking ease of move-
ment of footbrake lever
( 23)
Checking ease of move-
ment of shift lever ( 24)
Cleaning slider tubes ( 25)
Checking steering-head
bearing ( 25)
Checking wheel bearing for
play ( 26)
Checking telescopic-fork
protector and slip-ring
( 26)
Bleeding telescopic forks
( 27)
Checking ease of move-
ment of side stand ( 27)
Check operation of side-
stand switch ( 27)
Checking spring-strut
mount for play ( 28)
Checking swinging-arm
bearings for play ( 28)
Checking flexible gaiter
( 29)
2
6
z Overview

Checking Paralever bearing
for play ( 29)
Checking security of
threaded fasteners ( 29)
Work to be undertaken
once a year
Changing telescopic-fork oil
( 29)
2
7
z Overview

2
8
z Overview

Installing and removing components
Installing and removing
components
Removing number-plate
carrier ........................ 10
Installing number-plate
carrier ........................ 11
Removing mirror............... 12
Installing mirrors............... 12
Installing headlight guard . . .... 12
Installing guard for final drive . . . 13
Installing cylinder guard........ 14
Installing deflector for footbrake
lever . ......................... 14
Installing left and right hand
protectors . .................... 15
Replacing left and right hand
frame-protector strips ......... 18
3
9
z Installing and removing components

Removing number-
plate carrier
Make sure the ground is
level and firm and place the
motorcycle on its stand.
Remove the seat.
Remove plug 1from its
holder and disconnect the
plug.
Remove protective plug 2
from its holder.
Connect plug 1to protect-
ive plug 2.
Push wiring-harness end
of plug 1into the holder of
protective plug 2.
Remove screws 3on left
and right.
Remove screws 4and
screw 5.
Remove the number-plate
carrier and thread out the
cables.
Reinstall screws 4.
3
10
z Installing and removing components

Installing number-
plate carrier
Remove screws 4.
Manoeuvre the cables into
place and hold the number-
plate carrier in position.
Install screws 4and
screw 5.
Disconnect the number-
plate plug and the protect-
ive plug.
Install screws 3on left and
right.
Remove wiring-harness end
of plug 1from the holder.
Connect plug 1and seat it
in the holder.
3
11
z Installing and removing components

Seat protective plug 2in its
holder.
Install the seat.
Removing mirror
Push back rubber sleeve 1.
Release threaded fastener 2
and remove the mirror.
Remove clamping piece 3.
Installing mirrors
Install clamping piece 3.
Clamping piece to clamping
block
30 Nm
Install the mirror and adjust
it to the correct position.
Tighten threaded fastener 2.
Mirror to clamping piece
25 Nm
Slip rubber sleeve 1down
over the threaded fastener.
Installing headlight
guard
Use the headlight guard
only when off-roading.
Riding on public roads with
the headlight guard fitted to
the motorcycle is prohibited.
Position the headlight guard
with bore 1against the in-
strument carrier from be-
low and secure it with cable
tie 2.
3
12
z Installing and removing components

Bend the headlight guard
down at the front and use
cable ties 3to mudguard
struts 4.
In order to avoid injury,
be sure to turn the cable
tie so that the lock is at the
back.
Installing guard for
final drive
Insert attachment 1long
end toward the rear into
housing for final drive 2.
Position guard for final
drive 3on the attachment
and secure it with screw 4.
Guard, final-drive housing
8Nm
3
13
z Installing and removing components

Installing cylinder
guard
Remove screw 1.
Remove screws 2and 3.
Working from the inside,
insert the front reinforcing
plate into the cylinder
guard.
Use the screws and bush-
ings provided to secure the
cylinder guard, inserting
the screws into the tapped
holes left by the screws re-
moved beforehand.
Cylinder guard to engine
Thread-locking compound:
Mechanical thread lock
8Nm
Install cable tie 3.
In order to avoid injury,
be sure to turn the cable
tie so that the lock is at the
back.
Installing deflector for
footbrake lever
Screw threaded pin 2into
the tapped hole in the foot-
brake lever until nut 1can
just be screwed on.
Lock the pin with nut 1.
Footbrake lever deflector to
lever
Hand-tight
3
14
z Installing and removing components

Insert screw 3through
eye 4and install it in the
motorcycle's frame. Align
the eye as shown in the
illustration.
Footbrake lever deflector to
frame
5Nm
Remember to remove the
deflector for the footbrake
lever before you next use
the motorcycle on public
roads.
Installing left and right
hand protectors
Removing mirror ( 12)
Remove screws 1and
remove top part of mirror
clamping block 2. Hold the
clutch fitting or handbrake
fitting, as applicable, when
removing the clamping
block.
Install screws 1of the mirror
clamping block for the hand
protector, but do not tighten
them at this point.
Align the clamping block
so that pin 2of the grip unit
projects into the gap in the
mirror clamping block.
Tighten screws 1in such a
way that the gap between
the top and bottom halves
of the clamping block is
the same width at front and
rear.
Handlebar fitting to handle-
bar
3
15
z Installing and removing components

Position holders 3in such
a way that the cables pass
through recess 4. Note the
identifying marks RK for the
right hand protector and LK
for the left hand protector.
Install screws 5, but do not
tighten them at this point.
Use screws 6and
washers to secure the
hand-protector holder to
the hand protector. Use
hand-protector holder
7 684 575 for the left side
and 7 684 576 for the right
side.
Hand protector to holder for
hand protector
3Nm
Use screw 7and washer to
secure the hand-protector
holder to the mirror clamp-
ing block.
Holder for hand protector to
mirror clamping block
3Nm
Use screw 8and washer to
secure the hand protector
to holder 3.
Hand protector to clamping
block
3Nm
Tighten screws 5of the
holder in such a way that
the gap between the top
and bottom halves of the
3
16
z Installing and removing components